Search results for: production process reliability

Authors: Hamzeh Soltanali, Abbas Rohani, A. H. S. Garmabaki, Mohammad Hossein Abbaspour-Fard, Adithya Thaduri

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Toward continuous innovation and high complexity of technological systems, the automotive manufacturing industry is also under pressure to implement adequate management strategies regarding availability and productivity. In this context, evaluation of system’s performance by considering reliability, availability and maintainability (RAM) methodologies can constitute for resilient operation, identifying the bottlenecks of manufacturing process and optimization of maintenance actions. In this paper, RAM parameters are evaluated for improving the operational performance of the fluid filling process. To evaluate the RAM factors through the behavior of states defined for such process, a systematic decision framework was developed. The results of RAM analysis revealed that that the improving reliability and maintainability of main bottlenecks for each filling workstation need to be considered as a priority. The results could be useful to improve operational performance and sustainability of production process.

Keywords: automotive, performance, reliability, RAM, fluid filling process

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Authors: Jyothirmayee Pola

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Ideally, a test-driven development (TDD) or agile or any other process should be able to define and implement performance, scalability, and reliability (PSR) of the product with a higher quality of service (QOS) and should have the ability to fix any PSR issues with lesser cost before it hits the production. Most PSR test strategies for new product introduction (NPI) include assumptions about production load requirements but never accurate. NPE (New product Enhancement) include assumptions for new features that are being developed whilst workload distribution for older features can be derived by analyzing production transactions. This paper talks about how to shift left PSR towards design phase of release management process to get better QOS w.r.t PSR for any product under development. It also explains the ROI for future customer onboarding both for Service Oriented Architectures (SOA) and Microservices architectures and how to define PSR requirements.

Keywords: component PSR, performance engineering, performance tuning, reliability, return on investment, scalability, system PSR

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Authors: Wannee Sutthachaidee

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The study of the production process of coconut-shell product in Amphawa, Samutsongkram Province is objected to study the pattern of the process of coconut-shell product by focusing in the 3 main processes which are inbound logistics process, production process and outbound process. The result of the research: There were 4 main results from the study. Firstly, most of the manufacturer of coconut-shell product is usually owned by a single owner and the quantity of the finished product is quite low and the main labor group is local people. Secondly, the production process can be divided into 4 stages which are pre-production process, production process, packaging process and distribution process. Thirdly, each 3 of the logistics process of coconut shell will find process which may cause the problem to the business but the process which finds the most problem is the production process because the production process needs the skilled labor and the quantity of the labor does not match with the demand from the customers. Lastly, the factors which affect the production process of the coconut shell can be founded in almost every process of the process such as production design, packaging design, sourcing supply and distribution management.

Keywords: production process, coconut-shell product, Amphawa District, inbound logistics process

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Authors: Stephen V. Crowder, Jonathan W. Lane

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With short production development times, there is an increased need to demonstrate product reliability relatively quickly with minimal testing. In such cases there may be few if any observed failures. Thus it may be difficult to assess reliability using the traditional reliability test plans that measure only time (or cycles) to failure. For many components, degradation measures will contain important information about performance and reliability. These measures can be used to design a minimal test plan, in terms of number of units placed on test and duration of the test, necessary to demonstrate a reliability goal. In this work we present a case study involving an electronic component subject to degradation. The data, consisting of 42 degradation paths of cycles to failure, are first used to estimate a reliability function. Bootstrapping techniques are then used to perform power studies and develop a minimal reliability test plan for future production of this component.

Keywords: degradation measure, time to failure distribution, bootstrap, computational science

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Authors: Won Jung, Wan Emri

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Ferrite magnet is widely used in many automotive components such as motors and alternators. Magnets used inside the components must be in good quality to ensure the high level of performance. The purpose of this study is to design input parameters that optimize the ferrite magnet production process to ensure the quality and reliability of manufactured products. Design of Experiments (DOE) and Statistical Process Control (SPC) are used as mutual supplementations to optimize the process. DOE and SPC are quality tools being used in the industry to monitor and improve the manufacturing process condition. These tools are practically used to maintain the process on target and within the limits of natural variation. A mixed Taguchi method is utilized for optimization purpose as a part of DOE analysis. SPC with proportion data is applied to assess the output parameters to determine the optimal operating conditions. An example of case involving the monitoring and optimization of ferrite magnet process was presented to demonstrate the effectiveness of this approach. Through the utilization of these tools, reliable magnets can be produced by following the step by step procedures of proposed framework. One of the main contributions of this study was producing the crack free magnets by applying the proposed parameter design.

Keywords: ferrite magnet, crack, reliability, process optimization, Taguchi method

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Authors: S. Kreitlein, N. Eder, J. Franke

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The importance of energy efficiency within the production process increases steadily. Unfortunately, so far no tools for a comprehensive assessment of energy efficiency within the production process exist. Therefore the Institute for Factory Automation and Production Systems of the Friedrich-Alexander-University Erlangen-Nuremberg has developed two methods with the goal of achieving transparency and a quantitative assessment of energy efficiency: EEV (Energy Efficiency Value) and EPE (Energetic Process Efficiency). This paper describes the basics and state of the art as well as the developed approaches.

Keywords: energy efficiency, energy efficiency value, energetic process efficiency, production

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Authors: Khalid M. Albarkoly, Kenneth S. Park

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The substantial development of the construction industry has forced the cement industry, its major support, to focus on achieving maximum productivity to meet the growing demand for this material. Statistics indicate that the demand for cement rose from 1.6 billion metric tons (bmt) in 2000 to 4bmt in 2013. This means that the reliability of a production system needs to be at the highest level that can be achieved by good maintenance. This paper studies the extent to which the implementation of RCM is needed as a strategy for increasing the reliability of the production systems component can be increased, thus ensuring continuous productivity. In a case study of four Libyan cement factories, 80 employees were surveyed and 12 top and middle managers interviewed. It is evident that these factories usually breakdown more often than once per month which has led to a decline in productivity, they cannot produce more than 50% of their designed capacity. This has resulted from the poor reliability of their production systems as a result of poor or insufficient maintenance. It has been found that most of the factories’ employees misunderstand maintenance and its importance. The main cause of this problem is the lack of qualified and trained staff, but in addition, it has been found that most employees are not found to be motivated as a result of a lack of management support and interest. In response to these findings, it has been suggested that the RCM strategy should be implemented in the four factories. The paper shows the importance of considering the development of maintenance strategies through the implementation of RCM in these factories. The purpose of it would be to overcome the problems that could reduce the level of reliability of the production systems. This study could be a useful source of information for academic researchers and the industrial organisations which are still experiencing problems in maintenance practices.

Keywords: Libyan cement industry, reliability centred maintenance, maintenance, production, reliability

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Authors: Mohd Azman Abdul Latif, Erwan Basiron

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A flaw or drift from expected operational performance in one component (NAND, PMIC, controller, DRAM, etc.) may affect the reliability of the entire Solid State Drive (SSD) system. Therefore, it is important to ensure the required quality of each individual component through qualification testing specified using standards or user requirements. Qualification testing is time-consuming and comes at a substantial cost for product manufacturers. A highly technical team, from all the eminent stakeholders is embarking on reliability prediction from beginning of new product development, identify critical to reliability parameters, perform full-blown characterization to embed margin into product reliability and establish control to ensure the product reliability is sustainable in the mass production. The paper will discuss a comprehensive development framework, comprehending SSD end to end from design to assembly, in-line inspection, in-line testing and will be able to predict and to validate the product reliability at the early stage of new product development. During the design stage, the SSD will go through intense reliability margin investigation with focus on assembly process attributes, process equipment control, in-process metrology and also comprehending forward looking product roadmap. Once these pillars are completed, the next step is to perform process characterization and build up reliability prediction modeling. Next, for the design validation process, the reliability prediction specifically solder joint simulator will be established. The SSD will be stratified into Non-Operating and Operating tests with focus on solder joint reliability and connectivity/component latent failures by prevention through design intervention and containment through Temperature Cycle Test (TCT). Some of the SSDs will be subjected to the physical solder joint analysis called Dye and Pry (DP) and Cross Section analysis. The result will be feedbacked to the simulation team for any corrective actions required to further improve the design. Once the SSD is validated and is proven working, it will be subjected to implementation of the monitor phase whereby Design for Assembly (DFA) rules will be updated. At this stage, the design change, process and equipment parameters are in control. Predictable product reliability at early product development will enable on-time sample qualification delivery to customer and will optimize product development validation, effective development resource and will avoid forced late investment to bandage the end-of-life product failures. Understanding the critical to reliability parameters earlier will allow focus on increasing the product margin that will increase customer confidence to product reliability.

Keywords: e2e reliability prediction, SSD, TCT, solder joint reliability, NUDD, connectivity issues, qualifications, characterization and control

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Authors: Anurag Savarnya

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The reliability of the various parts of electric mining shovel has been assessed through the application of Weibull Model. The study was initiated to find reliability of components of electric mining shovel. The paper aims to optimize the reliability of components and increase the life cycle of component. A multilevel decomposition of the electric mining shovel was done and maintenance records were used to evaluate the failure data and appropriate system characterization was done to model the system in terms of reasonable number of components. The approach used develops a mathematical model to assess the reliability of the electric mining shovel components. The model can be used to predict reliability of components of the hydraulic mining shovel and system performance. Reliability is an inherent attribute to a system. When the life-cycle costs of a system are being analyzed, reliability plays an important role as a major driver of these costs and has considerable influence on system performance. It is an iterative process that begins with specification of reliability goals consistent with cost and performance objectives. The data were collected from an Indian open cast coal mine and the reliability of various components of the electric mining shovel has been assessed by following a Weibull Model.

Keywords: reliability, Weibull model, electric mining shovel

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Authors: R. A. Deshpande, P. Chandhra Sekhar, V. Sankar

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In this paper, we discussed the basic reliability evaluation techniques needed to evaluate the reliability of distribution systems which are applied in distribution system planning and operation. Basically, the reliability study can also help to predict the reliability performance of the system after quantifying the impact of adding new components to the system. The number and locations of new components needed to improve the reliability indices to certain limits are identified and studied.

Keywords: distribution system, reliability indices, urban feeder, rural feeder

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Authors: Manthan Patel, Vinit Ahlawat, Anshh Singh Claire, Pijush Samui

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This paper focuses on the analysis of quicksand condition for a dam foundation. The quicksand condition occurs in cohesion less soil when effective stress of soil becomes zero. In a dam, the saturated sediment may appear quite solid until a sudden change in pressure or shock initiates liquefaction. This causes the sand to form a suspension and lose strength hence resulting in failure of dam. A soil profile shows different properties at different points and the values obtained are uncertain thus reliability analysis is performed. The reliability is defined as probability of safety of a system in a given environment and loading condition and it is assessed as Reliability Index. The reliability analysis of dams under quicksand condition is carried by Gaussian Process Regression (GPR). Reliability index and factor of safety relating to liquefaction of soil is analysed using GPR. The results of reliability analysis by GPR is compared to that of conventional method and it is demonstrated that on applying GPR the probabilistic analysis reduces the computational time and efforts.

Keywords: factor of safety, GPR, reliability index, quicksand

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Authors: Raed KOUTA, José-Alcebiades-Ernesto HLUNGUANE, Eric Châtele

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The search for and exploitation of new fossil energy resources is taking place in the context of the gradual depletion of existing deposits. Despite the adoption of international targets to combat global warming, the demand for fuels continues to grow, contradicting the movement towards an energy-efficient society. The increase in the share of offshore in global hydrocarbon production tends to compensate for the depletion of terrestrial reserves, thus constituting a major challenge for the players in the sector. Through the economic potential it represents, and the energy independence it provides, offshore exploitation is also a challenge for States such as Mozambique, which have large maritime areas and whose environmental wealth must be considered. The exploitation of new reserves on economically viable terms depends on available technologies. The development of deep and ultra-deep offshore requires significant research and development efforts. Progress has also been made in managing the multiple risks inherent in this activity. Our study proposes a reliability approach to develop products and processes designed to live at sea. Indeed, the context of an offshore platform requires highly reliable solutions to overcome the difficulties of access to the system for regular maintenance and quick repairs and which must resist deterioration and degradation processes. One of the characteristics of failures that we consider is the actual conditions of use that are considered 'extreme.' These conditions depend on time and the interactions between the different causes. These are the two factors that give the degradation process its dynamic character, hence the need to develop dynamic reliability models. Our work highlights mathematical models that can explicitly manage interactions between components and process variables. These models are accompanied by numerical resolution methods that help to structure a dynamic reliability approach in a physical and probabilistic context. The application developed makes it possible to evaluate the reliability, availability, and maintainability of a floating storage and unloading platform for liquefied natural gas production.

Keywords: dynamic reliability, offshore plateform, stochastic process, uncertainties

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Authors: Gökhan Kayili, Ramazan Ari

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In this research, it is aimed to be adapted Wally Feelings Test to Turkish children and performed the reliability and validity analysis of the test. The sampling of the research was composed of three to five year-old 699 Turkish preschoolers who are attending official and private nursery school. The schools selected with simple random sampling method by considering different socio economic conditions and different central district in Konya. In order to determine reliability of Wally Feelings Test, internal consistency coefficients (KR-20), split-half reliability and test- retest reliability analysis have been performed. During validation process construct validity, content/scope validity and concurrent/criterion validity were used. When validity and reliability of the test examined, it is seen that Wally Feelings Test is a valid and reliable instrument to evaluate three to five year old Turkish children’s understanding feeling skills.

Keywords: reliability, validity, wally feelings test, social sciences

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Authors: Alonggot Limcharoen, Jintana Wannarat, Vorawat Panich

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This study aims to investigate the balancing of the number of operators (Line Balancing technique) in the production line of hard disk drive components in order to increase efficiency. At present, the trend of using hard disk drives has continuously declined leading to limits in a company’s revenue potential. It is important to improve and develop the production process to create market share and to have the ability to compete with competitors with a higher value and quality. Therefore, an effective tool is needed to support such matters. In this research, the Arena program was applied to analyze the results both before and after the improvement. Finally, the precedent was used before proceeding with the real process. There were 14 work stations with 35 operators altogether in the RA production process where this study was conducted. In the actual process, the average production time was 84.03 seconds per product piece (by timing 30 times in each work station) along with a rating assessment by implementing the Westinghouse principles. This process showed that the rating was 123% underlying an assumption of 5% allowance time. Consequently, the standard time was 108.53 seconds per piece. The Takt time was calculated from customer needs divided by working duration in one day; 3.66 seconds per piece. Of these, the proper number of operators was 30 people. That meant five operators should be eliminated in order to increase the production process. After that, a production model was created from the actual process by using the Arena program to confirm model reliability; the outputs from imitation were compared with the original (actual process) and this comparison indicated that the same output meaning was reliable. Then, worker numbers and their job responsibilities were remodeled into the Arena program. Lastly, the efficiency of production process enhanced from 70.82% to 82.63% according to the target.

Keywords: hard disk drive, line balancing, ECRS, simulation, arena program

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Authors: R. B. Patil, B. S. Kothavale, L. Y. Waghmode

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Today, the CNC turning center becomes an important machine tool for manufacturing industry worldwide. However, as the breakdown of a single CNC turning center may result in the production of an entire plant being halted. For this reason, operations and preventive maintenance have to be minimized to ensure availability of the system. Indeed, improving the availability of the CNC turning center as a whole, objectively leads to a substantial reduction in production loss, operating, maintenance and support cost. In this paper, fault tree analysis (FTA) method is used for reliability analysis of CNC turning center. The major faults associated with the system and the causes for the faults are presented graphically. Boolean algebra is used for evaluating fault tree (FT) diagram and for deriving governing reliability model for CNC turning center. Failure data over a period of six years has been collected and used for evaluating the model. Qualitative and quantitative analysis is also carried out to identify critical sub-systems and components of CNC turning center. It is found that, at the end of the warranty period (one year), the reliability of the CNC turning center as a whole is around 0.61628.

Keywords: fault tree analysis (FTA), reliability analysis, risk assessment, hazard analysis

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Authors: Chitaranjan Sharma

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The present paper deals with the analysis of a fuel supply system in an automobile engine of a four wheeler which is having both the option of fuel i.e. PETROL and CNG. Since CNG is cheaper than petrol so the priority is given to consume CNG as compared to petrol. An automatic switch is used to start petrol supply at the time of failure of CNG supply. Using regenerative point technique with Markov renewal process, the reliability characteristics which are useful to system designers are obtained.

Keywords: reliability, redundancy, repair time, transition, probability, regenerative points, markov renewal, process

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Authors: Rhadinia Tayag-Relanes, Felina C. Young

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This study was conducted to analyze the noodle production process at Yan Hu Food Manufacturing for the basis of production improvement. The study utilized the PDCA approach and record review in the gathering of data for the calendar year 2019 from August to October data of the noodle products miki, canton, and misua. Causal-comparative research was used in this study; it attempts to establish cause-effect relationships among the variables such as descriptive statistics and correlation, both were used to compute the data gathered. The study found that miki, canton, and misua production has different cycle time sets for each production and has different production outputs in every set of its production process and a different number of wastages. The company has not yet established its allowable rejection rate/ wastage; instead, this paper used a 1% wastage limit. The researcher recommended the following: machines used for each process of the noodle product must be consistently maintained and monitored; an assessment of all the production operators by checking their performance statistically based on the output and the machine performance; a root cause analysis for finding the solution must be conducted; and an improvement on the recording system of the input and output of the production process of noodle product should be established to eliminate the poor recording of data.

Keywords: production, continuous improvement, process, operations, PDCA

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Authors: Mayada Attia Ibrahim

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Evaluating and developing the electroplating production process is a key challenge in this type of process. The process is influenced by several factors such as process parameters, process costs, and production environments. Analyzing and optimizing all these factors together requires extensive analytical techniques that are not available in real-case industrial entities. This paper presents a practice-based framework for the evaluation and optimization of some of the crucial factors that affect the costs and production times associated with this type of process, energy costs, material costs, and product flow times. The proposed approach uses Design of Experiments, Discrete-Event Simulation, and Theory of Constraints were respectively used to identify the most significant factors affecting the production process and simulate a real production line to recognize the effect of these factors and assign possible bottlenecks. Several scenarios are generated as corrective strategies for improving the production line. Following that, data envelopment analysis CCR input-oriented DEA model is used to evaluate and optimize the suggested scenarios.

Keywords: electroplating process, simulation, design of experiment, performance optimization, theory of constraints, data envelopment analysis

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Authors: Mehul Srivastava, Sharma Tushar Ravikant, Mridul Krishn Mishra

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In structural design, the evaluation of safety and probability failure of structure is of significant importance, mainly when the variables are random. On real structures, structural reliability can be evaluated obtaining an implicit limit state function. The structural reliability limit state function is obtained depending upon the statistically independent variables. In the analysis of reliability, we considered the statistically independent random variables to be the load intensity applied and the depth or height of the beam member considered. There are many approaches for structural reliability problems. In this paper Extreme Learning Machine technique and First Order Second Moment Method is used to determine the reliability indices for the same set of variables. The reliability index obtained using ELM is compared with the reliability index obtained using FOSM. Higher the reliability index, more feasible is the method to determine the reliability.

Keywords: reliability, reliability index, statistically independent, extreme learning machine

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Authors: Abdel-Aziz M. Mohamed

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This research proposes a methodology to estimate the customer order lead time in the supply chain based on the process capability index. The cases when the process output is normally distributed and when it is not are considered. The relationships between the system capability indices in both service and manufacturing applications, delivery system reliability and the percentages of orders delivered after their promised due dates are presented. The proposed method can be used to examine the current process capability to deliver the orders before the promised lead-time. If the system was found to be incapable, the method can be used to help revise the current lead-time to a proper value according to the service reliability level selected by the management. Numerical examples and a case study describing the lead time estimation methodology and testing the system capability of delivering the orders before their promised due date are illustrated.

Keywords: lead-time estimation, process capability index, delivery system reliability, statistical analysis, service achievement index, service quality

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Authors: Pavol Tanuska, Pavel Vazan, Michal Kebisek, Dominika Jurovata

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The paper gives the results of the project that was oriented on the usage of knowledge discoveries from production systems for needs of the hierarchical process control. One of the main project goals was the proposal of knowledge discovery model for process control. Specifics data mining methods and techniques was used for defined problems of the process control. The gained knowledge was used on the real production system, thus, the proposed solution has been verified. The paper documents how it is possible to apply new discovery knowledge to be used in the real hierarchical process control. There are specified the opportunities for application of the proposed knowledge discovery model for hierarchical process control.

Keywords: hierarchical process control, knowledge discovery from databases, neural network, process control

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Authors: Reina Kawase

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Japan set the goal of 80% reduction in GHG emissions by 2050. To consider countermeasures for reducing GHG emission, the production estimation of energy intensive materials, such as steel, is essential. About 50% of steel production is exported in Japan, so it is necessary to consider steel production including export. Steel productions from 2005-2050 in Japan were estimated under various global assumptions based on combination of scenarios such as goods trade scenarios and steel making process selection scenarios. Process selection scenarios decide volume of steel production by process (basic oxygen furnace and electric arc furnace) with considering steel consumption projection, supply-demand balance of steel, and scrap surplus. The range of steel production by process was analyzed. Maximum steel production was estimated under the scenario which consumes scrap in domestic steel production at maximum level. In 2035, steel production reaches 149 million ton because of increase in electric arc furnace steel. However, it decreases towards 2050 and amounts to 120 million ton, which is almost same as a current level. Minimum steel production is under the scenario which assumes technology progress in steel making and supply-demand balance consideration in each region. Steel production decreases from base year and is 44 million ton in 2050.

Keywords: goods trade scenario, steel making process selection scenario, steel production, global warming

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Authors: Lakhoua Najeh

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Aims of the work: The aim of this paper is to improve the reliability and the availability of a Packer production line of cigarettes based on two methods: The SADT method (Structured Analysis Design Technique) and the FMECA approach (Failure Mode Effects and Critically Analysis). The first method enables us to describe the functionality of the Packer production line of cigarettes and the second method enables us to establish an FMECA analysis. Methods: The methodology adopted in order to contribute to the improvement of the reliability and the availability of a Packer production line of cigarettes has been proposed in this paper, and it is based on the use of Structured Analysis Design Technique (SADT) and Failure mode, effects, and criticality analysis (FMECA) methods. This methodology consists of using a diagnosis of the existing of all of the equipment of a production line of a factory in order to determine the most critical machine. In fact, we use, on the one hand, a functional analysis based on the SADT method of the production line and on the other hand, a diagnosis and classification of mechanical and electrical failures of the line production by their criticality analysis based on the FMECA approach. Results: Based on the methodology adopted in this paper, the results are the creation and the launch of a preventive maintenance plan. They contain the different elements of a Packer production line of cigarettes; the list of the intervention preventive activities and their period of realization. Conclusion: The diagnosis of the existing state helped us to found that the machine of cigarettes used in the Packer production line of cigarettes is the most critical machine in the factory. Then this enables us in the one hand, to describe the functionality of the production line of cigarettes by SADT method and on the other hand, to study the FMECA machine in order to improve the availability and the performance of this machine.

Keywords: production system, diagnosis, SADT method, FMECA method

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Authors: Sergo Tsiramua, Sulkhan Sulkhanishvili, Elisabed Asabashvili, Lazare Kvirtia

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The paper presents logical-probabilistic methods, models, and algorithms for reliability assessment of complex systems, based on which a web application for structural analysis and reliability assessment of systems was created. It is important to design systems based on structural analysis, research, and evaluation of efficiency indicators. One of the important efficiency criteria is the reliability of the system, which depends on the components of the structure. Quantifying the reliability of large-scale systems is a computationally complex process, and it is advisable to perform it with the help of a computer. Logical-probabilistic modeling is one of the effective means of describing the structure of a complex system and quantitatively evaluating its reliability, which was the basis of our application. The reliability assessment process included the following stages, which were reflected in the application: 1) Construction of a graphical scheme of the structural reliability of the system; 2) Transformation of the graphic scheme into a logical representation and modeling of the shortest ways of successful functioning of the system; 3) Description of system operability condition with logical function in the form of disjunctive normal form (DNF); 4) Transformation of DNF into orthogonal disjunction normal form (ODNF) using the orthogonalization algorithm; 5) Replacing logical elements with probabilistic elements in ODNF, obtaining a reliability estimation polynomial and quantifying reliability; 6) Calculation of “weights” of elements of system. Using the logical-probabilistic methods, models and algorithms discussed in the paper, a special software was created, by means of which a quantitative assessment of the reliability of systems of a complex structure is produced. As a result, structural analysis of systems, research, and designing of optimal structure systems are carried out.

Keywords: complex systems, logical-probabilistic methods, orthogonalization algorithm, reliability of systems, “weights” of elements

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Authors: Shiva Abdoli, Daniel T.Semere

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Several researches have been conducted to study consumption of energy in cutting process. Most of these researches are focusing to measure the consumption and propose consumption reduction methods. In this work, the relation between the cutting parameters and the consumption is investigated in order to establish a generalized energy consumption model that can be used for process and production planning in real production lines. Using the generalized model, the process planning will be carried out by taking into account the energy as a function of the selected process parameters. Similarly, the generalized model can be used in production planning to select the right operational parameters like batch sizes, routing, buffer size, etc. in a production line. The description and derivation of the model as well as a case study are given in this paper to illustrate the applicability and validity of the model.

Keywords: process parameters, cutting process, energy efficiency, Material Removal Rate (MRR)

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Authors: Ahmed Belgasem, Walid Ben Hussin, Emad Krekshi, Jamal Hashad

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Waxy crude oil, characterized by its high paraffin wax content, poses significant challenges in the oil & gas industry due to its increased viscosity and semi-solid state at reduced temperatures. The wax formation process, which includes precipitation, crystallization, and deposition, becomes problematic when crude oil temperatures fall below the wax appearance temperature (WAT) or cloud point. Addressing these issues, this paper introduces a technical solution designed to mitigate the wax appearance and enhance the oil production process in Abu-Attifil Field via a 30-inch crude oil pipeline. A comprehensive flow assurance study validates the feasibility and performance of this solution across various production rates, temperatures, and operational scenarios. The study's findings indicate that maintaining the crude oil's temperature above a minimum threshold of 63°C is achievable through the strategic placement of two heating stations along the pipeline route. This approach effectively prevents wax deposition, gelling, and subsequent mobility complications, thereby bolstering the overall efficiency, reliability, safety, and economic viability of the production process. Moreover, this solution significantly curtails the environmental repercussions traditionally associated with wax deposition, which can accumulate up to 7,500kg. The research methodology involves a comprehensive flow assurance study to validate the feasibility and performance of the proposed solution. The study considers various production rates, temperatures, and operational scenarios. It includes crude oil analysis to determine the wax appearance temperature (WAT), as well as the evaluation and comparison of operating options for the heating stations. The study's findings indicate that the proposed solution effectively prevents wax deposition, gelling, and subsequent mobility complications. By maintaining the crude oil's temperature above the specified threshold, the solution improves the overall efficiency, reliability, safety, and economic viability of the oil production process. Additionally, the solution contributes to reducing environmental repercussions associated with wax deposition. The research conclusion presents a technical solution that optimizes oil production in the Abu-Attifil Field by addressing wax formation problems through the strategic placement of two heating stations. The solution effectively prevents wax deposition, improves overall operational efficiency, and contributes to environmental sustainability. Further research is suggested for field data validation and cost-benefit analysis exploration.

Keywords: oil production, wax depositions, solar cells, heating stations

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Authors: Okoro Ikechukwu Ralph, Fuat Kara

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The discoveries of hydrocarbon reserves has clearly drifted offshore, and in deeper waters - areas where the industry still has limited knowledge; and that were hitherto, regarded as being out of reach. This shift presents significant and increased challenges in technology requirements needed to guarantee safety of personnel, environment and equipment; ensure high reliability of installed equipment; and provide high level of confidence in security of investment and company reputation. Nowhere are these challenges more apparent than on subsea well integrity and production performance. The past two decades has witnessed enormous rise in deep and ultra-deep water offshore field developments for the recovery of hydrocarbons. Subsea installed equipment at the seabed has been the technology of choice for these developments. This paper discusses the role of Subsea Control module (SCM) as a vital factor for deep-water well integrity and production performance. A case study for Deep-water well integrity and production performance is analysed.

Keywords: offshore reliability, production performance, subsea control module, well integrity

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Authors: Soroor K. H. Al-Khafaji, Manal Mohammad Abed

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The research aim of this paper is to evaluate the reliability of a complex engineering system and to design a fuzzy model for the reliability estimation. The designed model has been applied on Vegetable Oil Purification System (neutralization system) to help the specialist user based on the concept of FMEA (Failure Mode and Effect Analysis) to estimate the reliability of the repairable system at the vegetable oil industry. The fuzzy model has been used to predict the system reliability for a future time period, depending on a historical database for the two past years. The model can help to specify the system malfunctions and to predict its reliability during a future period in more accurate and reasonable results compared with the results obtained by the traditional method of reliability estimation.

Keywords: fuzzy logic, reliability, repairable systems, FMEA

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Authors: Sergo Tsiramua, Sulkhan Sulkhanishvili, Elisabed Asabashvili, Lazare Kvirtia

Abstract:

The paper presents logical-probabilistic methods, models and algorithms for reliability assessment of complex systems, based on which a web application for structural analysis and reliability assessment of systems was created. The reliability assessment process included the following stages, which were reflected in the application: 1) Construction of a graphical scheme of the structural reliability of the system; 2) Transformation of the graphic scheme into a logical representation and modeling of the shortest ways of successful functioning of the system; 3) Description of system operability condition with logical function in the form of disjunctive normal form (DNF); 4) Transformation of DNF into orthogonal disjunction normal form (ODNF) using the orthogonalization algorithm; 5) Replacing logical elements with probabilistic elements in ODNF, obtaining a reliability estimation polynomial and quantifying reliability; 6) Calculation of weights of elements. Using the logical-probabilistic methods, models and algorithms discussed in the paper, a special software was created, by means of which a quantitative assessment of the reliability of systems of a complex structure is produced. As a result, structural analysis of systems, research and designing of optimal structure systems are carried out.

Keywords: Complex systems, logical-probabilistic methods, orthogonalization algorithm, reliability, weight of element

Procedia PDF Downloads 36

Authors: Binjuan Xu, Qian Zhao, Ping Jiang, Bo Guo, Zhijun Cheng, Xiaoyue Wu

Abstract:

Astronautical valves are key units in engine systems of astronautical products; their reliability will influence results of rocket or missile launching, even lead to damage to staff and devices on the ground. Besides failure in engine system may influence the hitting accuracy and flight shot of missiles. Therefore high reliability is quite essential to astronautical products. There are quite a few literature doing research based on few failure test data to estimate valves’ reliability, thus this paper proposed a new method to estimate valves’ reliability, according to the corresponding tests of different failure modes, this paper takes advantage of tests data which acquired from temperature, vibration, and action tests to estimate reliability in every failure modes, then this paper has regarded these three kinds of tests as three stages in products’ process to integrate these results to acquire valves’ reliability. Through the comparison of results achieving from tests data and simulated data, the results have illustrated how to obtain valves’ reliability based on the few failure data with failure modes and prove that the results are effective and rational.

Keywords: censored data, temperature tests, valves, vibration tests

Procedia PDF Downloads 300